Food packaging insert and system

ABSTRACT

A food packaging system includes a packaging insert that is insertable into the base portion of a food container. The packaging insert includes a support member and at least one treated layer disposed on either the upper or lower surface of the support member. The support member is formed from a sheet of corrugated material. The packaging insert is configured to provide one or more desired properties to the food container.

REFERENCE TO RELATED APPLICATION

This application claims the benefit of priority under 35 U.S.C. § 119(e) of U.S. provisional application Ser. No. 62/423,273 filed on Nov. 16, 2016, which is hereby incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

The embodiments described herein relate generally to a packaging insert for use with a food container to retain heat, reduce moisture, resist oil stains, and/or provide other desired characteristics. The packaging inserts generally include a structural support made from e.g., folding carton board or corrugated board combined with one or more treated layers. A treated layer may comprise, e.g., a coating, laminated foil, laminated film, metalized film, or sputter coated paper.

At least some known containers are used for storing and/or transporting a heated or cooled food product therein in which the container is formed in a manner so as to provide one or more desired characteristics such as, e.g., heat retention. However, specially constructing containers to have desired properties may limit their flexibility (in terms of the number of applications they are suitable for) and may also entail significant additional expense.

As such, it would be desirable to provide one or more inserts that can be used in connection with a variety of containers and placed therein, under a food item, to provide one or more desired properties. Such inserts can be used at a much lower cost, and inserts can be made of a wide variety of materials that cannot be used during normal corrugation. Such inserts also allow the same container to be altered for many applications, depending on the insert used, reducing the required inventory for multiple applications.

BRIEF DESCRIPTION OF THE INVENTION

In one aspect, a food packaging insert includes a support member including a sheet of corrugated material. The support member defines an upper surface and a lower surface. The insert further includes at least one treated layer disposed on one of the upper surface and the lower surface. The food packaging insert is insertable into a food container and configured to provide one or more desired properties to the food container.

The sheet of corrugated material can include a sheet of single faced corrugated board.

The sheet of single faced corrugated board can define a plurality of flutes on the upper surface of the support member. The at least one treated layer can be disposed on the lower surface of the support member.

The at least one treated layer can include a metalized film.

The metalized film can include a metalized polyester film.

The one or more desired properties can include moisture control.

According to another aspect, a food packaging system includes a food container having a base portion and a closeable lid, and a packaging insert insertable into the base portion. The packaging insert includes a support member and at least one treated layer disposed on one of the support member's upper or lower surfaces. The support member includes a sheet of corrugated material. The packaging insert is configured to provide one or more desired properties to the food container.

The sheet of corrugated material can include a sheet of single faced corrugated board.

The sheet of single faced corrugated board can define a plurality of flutes on the upper surface of the support member. The at least one treated layer can be disposed on the lower surface of the support member.

The at least one treated layer can include a metalized film.

The metalized film can include a metalized polyester film.

The one or more desired properties can include moisture control.

The food container can be a pizza box and the one or more desired properties can include preserving the crunchiness or crispiness of a pizza stored within the pizza box

According to another aspect, a method of using a food packaging system includes placing an insert into the base portion of a food container beneath a pizza and closing the closeable lid.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1-6 show exemplary embodiments of the systems and inserts described herein.

FIG. 1 is a perspective view of a food packaging system including an insert and a food container, according to one embodiment of the present invention.

FIG. 2 is a perspective view of the system of FIG. 1, showing the insert placed within the tray or base portion of the food container.

FIG. 3 is a perspective view of the insert of FIG. 1.

FIG. 4 is a top view of the insert of FIG. 1.

FIG. 5 is a bottom view of the insert of FIG. 1.

FIG. 6 is a side view of the insert of FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description illustrates the disclosure by way of example and not by way of limitation. The description clearly enables one skilled in the art to make and use the disclosure, describes several embodiments, adaptations, variations, alternative, and use of the disclosure, including what is presently believed to be the best mode of carrying out the disclosure.

Referring to FIG. 1 there is shown a first embodiment of a food packaging system 10 that includes a packaging insert 12 that is insertable into an interior of a food container 14 (as shown in FIG. 2). In the illustrated embodiment, food container 14 is a conventional pizza box including a tray portion 16 and a closeable lid 18. The insert 12 can be placed over the interior surface of container's base panel 20. One or more food items (not shown) such as a pizza can then be placed directly onto an upper surface 22 of insert 12, and the container's lid 18 can then be closed.

FIGS. 3-6 show a variety of views of an insert 12. In the illustrated embodiment, insert 12 is generally flat or planar, and square or rectangular in shape, and sized so as to fit snugly within container 14 over base panel 20. However, inserts can be made in a variety of shapes and sizes. For example, in an alternative embodiment, insert could be circular in shape and sized so as to correspond to the underside of a pizza. Insert 12 has an upper surface 22 and a lower surface 24. In use, lower surface 24 is placed downwardly in face-contacting relationship with the upper surface of base panel 20. Upper surface 22 is positioned facing up so as to receive one or more food items placed thereupon.

Insert 12 comprises a structural support 28 and one or more treated layers 30 on the insert's lower and/or upper surfaces. In the illustrated embodiment, insert 12 comprises a single treated layer 30 defined on the insert's lower surface 24. Support member 28 can be formed from a generally flat or planar sheet of corrugated board or folding carton board. Alternatively, support member 28 can be formed from cardboard, plastic, fiberboard, paperboard, foamboard, corrugated paper, and/or any suitable material known to those skilled in the art and guided by the teachings herein provided. In the illustrated embodiment, support member 28 is formed from a single faced corrugated board comprising a flat linerboard 32 adhered to a corrugated medium 32 that defines a plurality of flutes 33. Any suitable flute size can be used such as, e.g., A flute, B flute, C flute, D flute, or E flute. The fluted side of support member 28 defines the top surface 22 of insert 12. Support member 28 is configured to provide structural support and rigidity to insert 12. In addition, the upward-facing flutes 33 of support member 28 may allow moisture to escape from the food item, thereby reducing sogginess. Support member 28 also acts as a layer of isolation/insulation between the food item and the base panel 20 and outside environment. Thus, support member 28 may facilitate heat retention while also reducing the risk that moisture or oil soaks or through bottom panel 20 of container 12. Moisture and/or oil that escapes from the food item may be absorbed into the material of support member 28. In addition, or alternatively, moisture and/or oil from the food item may collect in channels defined by flutes 33.

Treated layer 30 may comprise, e.g., a coating, laminated foil, laminated film, metalized film, or sputter coated paper. Exemplary materials from which treated layer 30 may be formed include, but are not limited to, aluminum foil (with or without a protective coating), metalized polymer films (such as oriented polypropylene, polyethylene terephthalate, nylon, polyethylene, cast polypropylene, polyester, and/or polyvinyl chloride), metalized paper, and/or non-metalized polymer films. In the preferred embodiment, treated layer 30 is a metalized polyester (met-PET) film laminated to the liner side/lower surface of support member 28. Empirical testing has shown that the use of an insert with a met-PET film laminated to the lower surface of a single faced corrugated support member may provide at least some heat retention benefit to a pizza box as compared to a pizza box using a control insert which included no lamination. Unexpectedly, the addition of a met-PET laminated film was also found to provide a significant benefit in terms of reducing the retained moisture in the pizza and increasing the pizza's crispiness or crunchiness. Surprisingly, this benefit was obtained even after the pizza was left in the box for an extended period of time (e.g., 35 minutes). Finally, the addition of a met-PET laminated film was shown to prevent moisture from leaking through the bottom of the pizza box. Moisture was observed trapped at the interface between the support member and met-PET laminated film.

One exemplary method of using the system will now be described. The food container 14 is opened and insert 12 is placed, with its top surface 22 facing up, into the interior of the tray portion 16 over the base panel 20. In certain embodiments, insert 12 may simply rest on base panel 20 without being secured thereto. In other embodiments, however, glue or other adhesive can be used to secure insert 12 to base panel 20. In other embodiments, insert 12 can be sized so as to be friction fit within the tray portion 16. In still other embodiments, other attachment means can be used to secure insert within tray portion 16. A food item such as a pizza is then placed onto the top surface 22 of insert 12 and the lid 18 is shut to close the container 14.

In an example embodiment, an insert and/or the food container with which it is used can include at least one marking thereon including, without limitation, indicia that communicates the product, a manufacturer of the product and/or a seller of the product. For example, the marking may include printed text that indicates a product's name and briefly describes the product, logos and/or trademarks that indicate a manufacturer and/or seller of the product, and/or designs and/or ornamentation that attract attention. In another embodiment, the insert and container are void of markings, such as, without limitation, indicia that communicates the product, a manufacturer of the product and/or a seller of the product. Furthermore, the container may have any suitable size, shape and/or configuration, i.e., any suitable number of sides having any suitable size, shape and/or configuration as described and/or illustrated herein. In one embodiment, the container includes a shape that provides functionality, such as a shape that facilitates packaging a food item, a shape that facilitates transporting the container, and/or a shape that facilitates stacking and/or arrangement of a plurality of containers. Similarly, the insert may have any suitable size, shape and/or configuration, such as a size and shape that facilitates insertion into a corresponding food container and/or a size and shape that facilitates stacking and/or arrangement of a plurality of inserts.

In the exemplary embodiment, an insert is provided with only a single treated layer on the insert's lower surface. However, in other embodiments, one or more treated layers may be provided on the upper and/or lower surfaces. In the exemplary embodiment, a single insert is used with the food container. However, in other embodiments, two or more inserts may be used having identical or different properties and may be, for example, stacked on top of another. In the exemplary embodiment, an insert is placed in the base of a food container underneath a food item. However, in other embodiments, one or more inserts may be placed over the food item and, for example, affixed to the interior surface of the container's lid. In the exemplary embodiment, the support member is formed from a single faced corrugated board. In other embodiments, the support member may be formed from, for example, a single wall, double wall, or triple wall corrugated board. In the exemplary embodiment, a food container is a conventional pizza box such as one formed from corrugated fiberboard. In other embodiments, one or more inserts may be used in combination with, for example, a pizza box made from a blank that includes a heat-reflective film adhered thereto.

Although specific features of various embodiments of the invention may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the invention, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims. 

What is claimed is:
 1. A food packaging insert comprising: a support member comprising a sheet of corrugated material, said support member defining an upper surface and a lower surface; and at least one treated layer disposed on one of said upper surface and said lower surface; wherein said food packaging insert is insertable into a food container and configured to provide one or more desired properties to said food container.
 2. The food packaging insert of claim 1, wherein said sheet of corrugated material comprises a sheet of single faced corrugated board.
 3. The food packaging insert of claim 2, wherein said sheet of single faced corrugated board defines a plurality of flutes on said upper surface of said support member, and wherein said at least one treated layer is disposed on said lower surface of said support member.
 4. The food packaging insert of claim 3, wherein said at least one treated layer comprises a metalized film.
 5. The food packaging insert of claim 4, wherein said metalized film comprises a metalized polyester film.
 6. The food packaging insert of claim 4, wherein said one or more desired properties comprises moisture control.
 7. A food packaging system comprising: a food container comprising a base portion and a closeable lid; and a packaging insert insertable into said base portion and comprising: a support member comprising a sheet of corrugated material, said support member defining an upper surface and a lower surface; and at least one treated layer disposed on one of said upper surface and said lower surface; wherein said packaging insert is configured to provide one or more desired properties to said food container.
 8. The food packaging system of claim 7, wherein said sheet of corrugated material comprises a sheet of single faced corrugated board.
 9. The food packaging system of claim 8, wherein said sheet of single faced corrugated board defines a plurality of flutes on said upper surface of said support member, and wherein said at least one treated layer is disposed on said lower surface of said support member.
 10. The food packaging system of claim 9, wherein said at least one treated layer comprises a metalized film.
 11. The food packaging system of claim 10, wherein said metalized film comprises a metalized polyester film.
 12. The food packaging system of claim 10, wherein said one or more desired properties comprises moisture control.
 13. The food packaging system of claim 10, wherein said food container comprises a pizza box and wherein said one or more desired properties comprises preserving the crunchiness or crispiness of a pizza stored within said pizza box.
 14. A method of using the food packaging system of claim 13 comprising placing said insert into said base portion of said food container beneath a pizza and closing said closeable lid. 